Hydrogen generator

ABSTRACT

There is provided a new and useful hydrogen generator for supplying hydrogen and/or oxygen to an internal combustion engine, the generator comprising a housing, a base unit secured within the housing, the base unit having integral therewith first mounting means for an electrolytic cell, second mounting means for a replaceable liquid reservoir, and a conduit between the first and second mounting means, an electrolytic cell mounted in the first mounting means, the cell having a liquid inlet and a gas outlet, and having connectors for electrical connection to an external source of energy, and a controller unit connected to the cell and comprising a central processing unit and a series of sensors for sensing pressure, temperature and liquid level in the cell, the controller controlling operation of the cell responsive to sensor output.

FIELD OF THE INVENTION

[0001] This invention relates to electrolytic hydrogen generators.

BACKGROUND OF THE INVENTION

[0002] It has been proposed to introduce a proportion of hydrogen and/or oxygen into a fuel mixture for burning in an internal combustion engine, in order to increase the efficiency of burning. The intended result is reduced noxious emissions to the environment, reduced engine maintenance and reduced fuel costs.

[0003] To date many devices have been proposed for this purpose, but none has come into widespread use.

PRIOR ART

[0004] Applicant is aware of the following Canadian Patents and published applications which pertain to this subject matter:

[0005] Canadian Patent Nos. 1,072.492; 1,092,546; 1,098,482; 1,165,695; 1,227,094; 1,231,872; 1,233,379; 1,234,774; 1,272,647; 1,289,506; 2,080,660.

[0006] Canadian Patent Application Nos. 2,085,386; 2,141,880; 2,158,068; 2,184,995; 2,207,116; 2,209,237; 2,227,128; 2.229,694; 2,241,846; 2,287,270; 2,368,508

BRIEF SUMMARY OF THE INVENTION

[0007] The invention provides a hydrogen generator which includes improved components in a novel structural combination.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] These and other advantages of the invention will become apparent upon reading the following detailed description and upon referring to the drawings in which:—

[0009]FIG. 1 is a perspective view of a hydrogen generator according to the invention;

[0010]FIG. 2 is a perspective view of the hydrogen generator of FIG. 1 with part of the housing removed;

[0011]FIG. 3 is an elevation with additional detail of the generator of FIG. 2;

[0012]FIG. 4 illustrates a base member for use in the generator of FIG. 2;

[0013]FIG. 5 illustrates a spacer for electrodes for the generator of FIG. 2;

[0014]FIG. 6 illustrates spiral electrodes for use in the generator of FIG. 2;

[0015]FIG. 7 is a perspective view of a part of a reservoir mounting for the generator of FIG. 2;

[0016]FIG. 8 is a cross section through the mounting part of FIG. 7;

[0017]FIG. 9 is a seal piercing device for the mounting part of FIG. 7:

[0018]FIG. 10 illustrates a reservoir access door in the housing of a generator according to the invention;

[0019]FIG. 11 illustrates the access door of FIG. 10 in an open position in plan; and

[0020]FIG. 12 is a perspective view of the access door of FIGS. 10 and 11

[0021] While the invention will be described in conjunction with illustrated embodiments, it will be understood that it is not intended to limit the invention to such embodiments. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

[0022] In the following description, similar features in the drawings have been given similar reference numerals.

[0023] Generator 10 includes housing 12 comprising rear wall 14 and cover 16.

[0024] A base member 18 comprising a first mounting means 20 and a second mounting means 22 is secured to back 14. A conduit 24 extends between first, mounting means 20 and second mounting means 22, integral with base member 18.

[0025] An electrolytic cell 26 is mounted in sealing engagement on mounting means 20, and a make-up liquid reservoir 28 is mounted in sealing engagement with mounting means 22.

[0026] A cooling fan 30 is provided to circulate cooling air over the cell 26 and the unit as a whole, responsive to a high temperature reading at a sensor provided for the purpose.

[0027] The cell 26 includes a housing comprising cylindrical body member 32 and top cover 34. Top cover 34 is provided with a first outlet 36 for gas produced by the cell and routed to an internal combustion engine; and a second outlet 38 leading to a vacuum pump 40 which is vented to atmosphere at 42.

[0028] Parts 32 and 34 of the cell are held together by closure band 44, enclosing a thermal spacer 46.

[0029] The cell comprises the electrodes 48 and 50, electrode 50 being fully immersed in an electrolyte 52 in part 32 of the cell 26. Any suitable electrolyte may be used. A common suitable electrolyte is KOH.

[0030] One suitable embodiment for electrodes 50 comprises a spiral mesh plate with the plates separated by spacer clips 52 and secured within insulating rings 54.

[0031] The electrolytic cell is driven via transformers 56. The transformers may provide a variable current input to vary the hydrogen output of the generator.

[0032] While detailed electrical connections are not shown, these are conventional, and the basic operation of the cell is conventional.

[0033] The cell 26 is preferably threadedly engaged with mounting means 20.

[0034] The make-up liquid reservoir 28 will normally comprise a source of water, the water being broken down in the electrolysis process to form hydrogen and oxygen. A means of connecting the reservoir 28 to the mounting means 22 is shown in FIGS. 7 to 9. A threaded opening 58 is secured in sealing engagement with mounting means 22. Piercing means 60, which includes a segmented base plate 62, is secured with the projections 64 projecting up into opening 58.

[0035] The preferred reservoir comprises a plastic bottle 66 having a conventional threaded neck (not shown) sized to threadedly engage threaded opening 58.

[0036] The plastic bottle is preferably provided with a foil seal across the opening adjacent the threaded neck, so that when the bottle is inverted and screwed into the opening 58, the projections 64 pierce the foil seal. Make-up liquid, suitably distilled water, is then free to flow from the reservoir.

[0037] A check valve 68 is provided in conduit 24, permitting flow only from the reservoir 28 to the cell 26, but not in the reverse direction.

[0038] A heating jacket 70 of any suitable configuration may be provided where the generator will be used in sub-freezing temperatures A similar jacket 72 may be provided on cell 26.

[0039] An electrolyte 52 is chosen which is useable over a very extended life cycle without the necessity to use makeup electrolyte. The make-up liquid from reservoir 28 is thus normally distilled water.

[0040] When make-up water is required, vacuum pump 40 is activated (as will be described below) to create a partial vacuum within the cell The product gas outlet 36 includes a check valve 70 to prevent product gases from being drawn back into the cell. The partial vacuum in the cell then draws make-up water from reservoir 28 through check valve 68.

[0041] The cell 26 includes an outlet drain 72 for removing electrolyte from the cell for cell maintenance or other purposes. The cap 34 of cell 26 is provided with a rupture disc 74 which will allow product gases to vent should an extreme pressure situation occur, thus preventing the danger of explosion.

[0042] FIGS. 10 to 12 illustrate an access door provided in the cover 16 of housing 12, provided to allow filled reservoir bottles to be inserted and empty reservoir bottles to be removed. The reservoir could be a permanent unit, filled by simply adding water from a jug, but it is cleaner and more precise to simply provide disposable reservoir bottles. These are as described earlier, with a foil or other seal across the neck opening and, for shipping and storage, a plastic cap applied in the normal manner.

[0043] To remove a bottle, the access door 76 is opened, and a used bottle simply unscrewed from mounting 22 and removed A new bottle is secured in the mounting, and the door 76 is then closed. Door 76 is provided with a cutting blade 78, placed to pierce the end of a reservoir bottle 28 positioned in mounting 22. This will simply allow air to enter the bottle as water is removed to prevent collapse of the bottle.

[0044] The blade 78 may be retractable when the access door is open and extended to the operating position as the door approaches the fully closed position, this arrangement clearly adding a safety factor.

[0045] The blade may also be mounted in a retractable manner within cover 16 adjacent mounting means 22.

[0046] Operation of the generator is controlled by a control system comprising a central processing unit, and a series of sensors. The sensors may sense temperature, pressure and liquid level in the electrolytic cell. Control valves, on/off switches and indicator lights are controlled by the CPU, responsive to sensed values.

[0047] The basic operation of the unit will be controlled by at least one sensed value from the internal combustion engine which is to be fed by the generator. One suitable parameter from the engine is the position of the ignition switch. Another is oil pressure.

[0048] The CPU will also record time of operation of the generator.

[0049] As well, the volume of gas generated for injection into the engine may be varied by varying the current through the cell. The current variation may be controlled by the CPU, responsive to other engine parameters, as, for example, a load indicator such as a torque measurement device.

[0050] A key sensor is that which indicates that the reservoir needs to be replaced (aqueous solution does not replenish). An indicator light is provided to alert an operator of this condition. In the case of a motor vehicle, the indicator light will be provided in the vehicle cab to alert the driver to replace the reservoir.

[0051] Thus, it is apparent that there has been provided in accordance with the invention an adjustable decking system that fully satisfies the objects, aims and advantages set forth above. While the invention has been described in conjunction with illustrated embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations as fall within the spirit and broad scope of the invention. What I/we claim as my/our invention: 

1. A hydrogen generator for supplying hydrogen and/or oxygen to an internal combustion engine, said generator comprising: a housing; a base unit secured within said housing, said base unit having integral therewith first mounting means for an electrolytic cell; second mounting means for a replaceable liquid reservoir, and a conduit between said first and second mounting means; an electrolytic cell mounted in said first mounting means, said cell having a liquid inlet and a gas outlet, and having connectors for electrical connection to an external source of energy; and a controller unit connected to said cell and comprising a central processing unit and a series of sensors for sensing pressure, temperature and liquid level in said cell, said controller controlling operation of said cell responsive to sensor output.
 2. The generator of claim 1 wherein said conduit includes a check valve for allowing flow only from said second mounting means to said first mounting means, and said second mounting means includes means for securing said reservoir, said means for securing including means integral therewith for piercing a seal on said reservoir to allow flow from said reservoir to said conduit.
 3. The generator of claim 2 wherein said means for securing comprises a mating threaded connection between said container and said mounting means, and said means for piercing comprises at least one upstanding member fixed in said mounting means such that, when said threaded connection is made, said upstanding member pierces said seal.
 4. The generator of claim 3 wherein said housing has mounted thereon, adjacent said second mounting means, second piercing means for piercing said container at a point on said container remote from said mounting means when said container is secured on said mounting means, to allow entry of air to said container.
 5. The generator of claim 3 wherein said housing includes an access door adjacent said second mounting means for inserting and removing said container into and from said second mounting means, and wherein said access door includes thereon second piercing means for piercing said container, responsive to closing of said access door, at a point on said container remote from said mounting means when said container is secured on said mounting means, to allow entry of air to said container.
 6. The generator of claim 2 wherein said cell includes in said gas outlet a check valve to prevent gas flow into said cell, and said cell further includes a second gas outlet and a vacuum pump operatively associated with said second outlet for creating a partial vacuum in said cell to draw liquid from said container into said cell.
 7. The generator of claim 6 wherein operation of said vacuum pump is controlled by said controller responsive to input from liquid level sensors in said cell.
 8. The generator of claim 1 including an electrically powered heating jacket for said cell, said jacket connected to an external source of electrical energy.
 9. The generator of claim 8 including an ambient air temperature sensor and wherein said heating jacket is controlled by said controller responsive to input from said ambient air temperature sensor.
 10. The generator of claim 1 wherein said second mounting means includes an electrically powered heating jacket for said reservoir, said jacket connected to an external source of electrical energy.
 11. The generator of claim 10 including an ambient air temperature sensor and wherein said heating jacket is controlled by said controller responsive to input from said ambient air temperature sensor.
 12. The generator of claim 1 wherein said generator is adapted for supplying gas from said cell to an internal combustion engine and is connected to the engine electrical systems; wherein said cell includes means for varying current input to said cell, and wherein said controller receives an input load signal from said engine related to the load on said engine, and said current is adjusted by said controller responsive to said load signal. 